Sustainability Analysis of Zn-Ni Plating and

Alternatives at Fleet Readiness Center Southeast

Michael Bruckner, Andrew Henderson, Drew Rak, Emma Williams, Kelly Scanlon (OSD)
In support of the Office of the Secretary of Defense (OSD)
Acknowledgments: Jack Benfer and Ruben Prado (FRCSE)

21-23 August, Denver, CO

ASETSDefense Workshop 2018

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 Agenda

I. Description of need/problem

II. Sustainability Analysis Overview

III. System Boundary

IV. Inventory

V. Results - Cost

VI. Results - Impacts

VII. Sensitivity

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 Statement of problem and need

■ Need to understand cost over life

cycle and ESOH impacts of switch to
Zn-Ni from Cd electroplating
■ OSD benefit:
• Test SA method and avoid burden-
shifting throughout portfolio
■ FRCSE benefit:
• high level picture of benefits and
drawbacks (cost, quantitative, and
qualitative) for new line.
• Can communicate results up the
command chain (e.g., build business
case)
LHE Zn-Ni Plating at Hill AFB.
Source Final Report ESTCP Project WP-201107

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 Method of analysis

Sustainability Analysis = LCC + LCA

Internal costs External costs
Total cost for use (and disposition) Environmental impacts
Compatible with DoD cost structures Indicators of potential future
liabilities

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 Costs are locked in early

There is a need to capture LCC comprehensively during system R&D

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 Steps for analysis

Step 3
Step 1 Step 2 Step 5
Estimate life cycle
Define the Develop a impacts Synthesize
scope life cycle results and
inventory Step 4 iterate
(LCI)
Estimate life cycle
costs (LCC)

Sustainability Analysis is a 5-step process

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 Scope and basis of comparison
Plated
Components
Components

Industrial
Process
Process Waste- Wastewater
water Plating Line
Electricity
water water Treatment
production
Tap (rinse) water Plant 2/3
Consumables
Defense Input Output
Materials
(DIO) Database Fuel

Exhaust stack/
Waste Air Emissions
Haz. Waste
scrubber

Background – Supply Chain Foreground

Costs and environmental impacts are compared per ft2 of plating over a 15-year line life span. The
analysis system boundary includes the plating line, support infrastructure, and the DoD supply chain.
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 Plating line: Cd baseline
COMPONENTS

Cadmium Plating Activity

Blast E-20 E-19 E-17 E-16 E-15 E-14

(glass beads or vapor) Electro Clean Rinse Tank Acid Activation Rinse Tank Nickel Strike Rinse Tank

Type II

E-4 E-3 E-2 E-1

Bake Type I
Cadmium Plate Rinse Tank Conversion Coat Rinse Tank

Process or
Rinse Tank

Not in COMPONENTS COMPONENTS

Process Line

The baseline includes a 15-year lifespan; capital costs associated with line installation are sunk.
Inputs and outputs for components with and without post-treatment are included.
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 Plating line: Zn-Ni alternative
COMPONENTS

Zn-Ni Plating Activity

Blast D-1 D-2 D-3 D-4 D-5 D-6

(glass beads or vapor) Electro Clean Rinse Tank Acid Activation Rinse Tank Zn-Ni Plate Rinse Tank

D-7 D-8 D-9 D-10 D-11

Bake
Acid Activation Rinse Tank TCP Post Treatment Rinse Tank Hot Rinse Tank

Process or
Rinse Tank
COMPONENTS
Not in
Process Line

The Zn-Ni alternative includes a 15-year lifespan and capital costs associated with line installation.
Additionally, high and low labor estimate scenarios were included.
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 Inventory example

Each modeled activity captures inputs, outputs, cost, and link to supply chain

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 Summarized data for comparison and communication

Item (annual, assuming Cd Zn-Ni

equivalent coating area)
Lbs Cd used at FRCSE 45 0
Process chemicals $ 9,400 $ 3,400
consumed
Labor (man-hours) 830 530 - 830

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 Process flow diagram, structured for LCA

Foreground data were collected from FRCSE, while background data from the Defense Input
Output Database (DIO) were used.
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 Life cycle costs (LCC)

Labor and capital investment are cost drivers

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 LCCs and O&M costs

Summary of LCCs
Cd - Baseline Zn-Ni (1) Zn-Ni (2)
PV of Investment Costs
Equipment & Materials $ - $ 1,387,000 $ 1,387,000
Labor $ - $ 500,000 $ 500,000
Waste Management $ - $ 150,000 $ 150,000
Total Investment $ - $ 2,037,000 $ 2,037,000
PV of Annual Costs
Labor $ 1,592,877 $ 1,592,877 $ 550,335
Materials $ 129,087 $ 46,342 $ 46,342
Utilities $ 717,087 $ 290,103 $ 290,103
Waste Management $ 722,501 $ 403,253 $ 403,253
Total Recurring $ 3,161,552 $ 2,332,575 $ 1,290,032
NPV $ 3,161,552 $ 4,369,575 $ 3,327,032

Life cycle operating and maintenance costs are lower for Zn-Ni than Cd plating

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 Life cycle impacts and external costs

$ external cost / m2
Life cycle impacts increasingly improve the more corrosion data impact the
maintenance cycle
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 Conclusions

■ Opportunities for improvement

• Continue gathering data
• Corrosion testing may indicate longer life of components or less frequent repair plating
• Continue gathering data related to Cd reduction

■ How can results be used?

• Can communicate results up the command chain (e.g., build business case)
• high level picture of benefits and drawbacks (cost, quantitative, and qualitative) for new line.

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Questions?

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